Professional Documents
Culture Documents
GROUP22
FUELSYSTEM
CONTENTS
Diagnosis. .. 22-6
FuelGaugeDiagnosis 22-7
Fuelfnjector Inspection. ........ 22-12
C h e c kO p e r a t i o n . .....,... 22-12
FuelLeakage Test.. .. . .. 22-12
fniectorResistance .. ... .. .. 22-13
V o l u mTee s t ....... 22-12
FuelLineHandling. .. 22-8
Primingthe FuelSystem 22-B
FuelPumpInspection. 22-9
HoldPressure ..... 22-10
F u eP l u m pM a x i m u P mr e s s u r e ........ 22-10
FuelPumpOperation. 22-9
FuefPumpBelayInspection .... 22-10
CheckOperation. .. 22-10
Continuity Inspection ........ 22-'l'1
GeneralDiagnosis .. ... .. 22-6
Pressure Regulator Inspection .. ... ..... 22-11
F u eL l i n eP r e s s u r e ......... 22-11
HofdPressure ..... 22-11
ReleasingFuelSystemPressure 22-A
SystemChecks 22-8
FuelLinePressureInspection 22-9
Fuel PressureHoldInspection 22-8
GeneralDescription ... ... 22-2
Air FuelInduction System. 22-2
Electronic FuelPumpAssembly ...... 22-2
FuelFilters 22-2
Fuel Pipesand Hoses. 22-3
Fuel PressureRegulatorValve .. 22-3
FuelSenderAssembly .... 22-3
FuelTank. .. 22-3
FuelTankPressure Sensor.. .. 22-3
On-Vehicfe Service.. ... 22-13
A i rC l e a n eErl e m e n. t ......... 22-30
AirCleaner Assembly andBracket. ....... 22-30
A i rF u n n e l ......... 22-3'l
Air IntakeHose.. . . .. 22-32
A i rf n t a k De uct.... ... 22-32
Checkand CutValve 22-25
Dynamicchamber .... 22-35
FreshAirDuct..... . .. 22-32
FuelDistributor. ...... 22-35
FuelFilter .. 22-29
Fuellnjectors ..... . .. 22-36
Fuel Lines 22-26
FuefPump. 22-19
FuelPumpAssembly ... .. .. . .. 22-15
FuelPumpAssembly Filter ..... 22-17
22-2 FUEL SYSTEM
z1-tJ
FuelTankSenderAssembly 22-21
FuelTankPr€ssureSensor. . 22-23
ldleAir ControlValve.. . . z1-,7,1
InjectorInsulators 22-38
I n l eP
t i p eA s s e m b l y . . . . . . . 22-r'7
MassAir FlowSensor. a1-,t I
PCVValveand Ventilation Hose.. . . 22-31
22-U
PressureRegulator. 22-30
Quickconnector. 22-43
ResonanceChamber
VaporSeparalorAssembly. 22-28
ThrottleBody 22-33
ThrottlePositionSensor.. 22-34
Specitications 22-44
FastenerTighteningSpecifications. 22-44
GeneralSpecifications
.... 22-44
12
&,_.-,,
G-
(il;EP
\-
20
1 . MassAir Flow(MAF)Sensor
Air Cleaner
.t. Resonance Chamber
4. ThrottleBody(lncludesThrottlePositionSensor)
Plenum
b . ldleAir Control
Valve
22.6 FUELSVSTEM
DIAGNOSIS
GENERAL
DIAGNOSIS
Problem PossibleCause Aclion
Engineclanks but will Fuelpressureproblem Replacefuelpressureregulator
not slan Replaceleakinginjeclor
ReplaceinjectorO-ring
Hald lo start (cold ldleair controlvalvenotworking Replace
en9ine) Detectivethrotlleposilionsensor Replacethrottlebody
Fuelpressuretoo low Replaceregulator
Coolanttempsensoropencircuitor out ot range Repairhamess
Beplacesensor
Rough idle (cold Throttlevalvesimproperly
adjusted Adjustthrottle
engine) Fuelinjectorflow Beplaceinjector
Throttleplalestuckopen Cleanand adjustthrottleplate
Adjustthrottlecable
Throttlef,osilion switchsluckopen Replace
ldleair controlvalveinoperative Replace
Air iniakeductdisconnected between Reconnect air duct
MAFand th.ottlebody
Leakinginjector Beplace
LeakinginjectorO-ringseals Replace
Slalling or hesitalion Throttlepositionsensorfailed ReplaceTP sensor
(hot or cold engine) EGFIvalvemalfunction Replace
Hard slart (hot engine) Inconectluel pressure Checkpressu.eregulalortuelpump
Stalls on quick stops or Mais air flowsensoropencircuitout ol range ReplaceMAFsensor
deceleration circuii(seeETM)
Checkelectrical
Pool pertormance/loss Cloggedinjectors Checkinjeclortlow rate
ot power Airfiherclogged Replace
FUELSYSTEM 22.7
FUELGAUGEDIAGNOSIS
Ploblem Possible Cause Action
Fuelgaugeshows Looseor dirtywiringconneclions
or shortto groundwiring Checkwiring,connecto.sandsenderassembly.
empty at all levelsol lill Repair,cleanor tightenas needed.
Leakingsenderfloat Beplacesender
Missingsendertloat Installfloat.Makesurefloatis secured
on sender
arm.
Shortcircuitin senderassembly Testtor conect resistancevaluesandreplaceas
needed.
Senderassembly
arm movement
obslructed Inspectfueltankand senderfor cause.Replace
faultycomponent.
Fuelgaugewill not Wrongsenderinstalled Checkpartnumber.It inconecl,installcorrectpart.
readtull when tank is Senderarmmovement (floatrodbent)
obstructed Inspectlueliank and senderfor cause.Replace
full taultycomponent.
Leakinglloat lnstallnewsender
Senderor gaugecalibration Testlor conect resisianceva[re andreplace
component as needed.
Fueltanknotfillingto ratedcapacity Checktueltankfill ventfor kinksor obstructions.
Correctas requiredandlill tankto verilyproper
capacity.
Fuelgaugeshows tull Looseor dirtywiringconnections
or opencircuitin wiring Checkwiring,connections andsenderlermtnaF.
ai all levelsol fill Repairor cleanit required.
Opencircuitin sendingunit Testlor correctresistancevaluesand replaceit
requrred.
Senderarmmovement
obslructed Inspectfueltankand sendertor cause.Gently
bendfloat arm awaylrom obstructionor
replacecomponent.
Inaccude indications Fuel lank damage Fuel sender mounting angle may have changedor
continuebut all fuel the sender unit may bs damaged.
syslem components
are runningproperly
22.8 FUEL SYSTEM
l(lar 63-22.{'a\s
SYSTEMCHECKS
FuelPressureHold Inspection
1. Disconnect the negativebatteryterminal.
A WARNING
1 FuelPumpAssembly THEFUELSYSTEMREMAINSUNDER
2 FuelPumpAssembly
ElectricalConneclor PRESSURE WHENTHE ENGINEIS NOT
RUNNING. BELEASEFUELSYSTEMPRESSURE
BEFOREDISCONNECTING ANY FUELLINETO
REDUCETHECHANCEOF PERSONAL INJURY
OR FIREDAMAGETO VEHICLECOMPONENTS.
FUELLINEHANDLING Releasefuelsystempressure. Referto "Releasing
A wanrurlc FuelSystemPressure"in this section.
FUELIS EXPLOSIVE. WHENWORKINGON Installa fuel pressuregaugeto the pressureport
FUELSYSTEMPARTS.MAKESURETO locatedon ihe frontof the fuel rail.
SUPPLYADEOUATEVENTILATION TO THE
WORKAREA.DO NOTSMOKE,AND KEEP
SPARKSAND OPENFLAMESAWAY.
1. Whendisconnecting fuelhoses,usea shoptowel
to absorbfuel,protectingequipmentand personnel.
2. Stopfuel leakageby installing
hoseclampswhere
thefuelfilterandthe mainfuelhoseconnectto the
luel pressuregauge.
Primingthe FuelSystem
Afterfuel pressurehas beenreleasedfor repairsor
inspection,the systemmustbe primedto avoidtoo
muchcrankingto restartthe engine.Followthe steps
below.
FUELSYSTEM 22-9
FUELPUMPINSPECTION
A uRl,tl1c
THE FUELSYSTEMREMA'NSUNDER
PRESSURE WHENTHEENGINEIS NOT
RUNNING.RELEASEFUELSYSTEMPRESSURE
BEFOREDISCONNECTINGANYFUELLINETO
REDUCETHECHANCEOF PERSONAL INJURY
OR FIREDAMAGETO VEHICLECOMPONENTS.
FuelPumpOperation
1. Connectthe datalinkconnectorterminalsFUEL
'rs
PUMPand B+witha iumoerwire.
Ktar6:122-t
FuelLine PressureInspection
1. Disconnectthe negativebatterycable.
2. Releasefuel systempressure.Referto "Releasing
FuelSystemPressure"in this section. 2. Removethe fuelfillercap.
3. lnstalla fuel pressuregaugeto the pressureport 3. Turnthe ignition switchON.
locatedon the frontof the fuel rail. 4. Determine if thefuelpumpis runningby listening
4. Connectthe negativebatterycable. for the soundof it at the fuel fillerinlet.
5. Installthefuelfillercap.
6. lf no soundwas heard,measurethe voltage
betweenthe fuel pumpconnectorwire (Gff) to
chassisground.
Voltage:About12V
7. lf the voltageis normal,replacethe tuel pump.
8. lf you do not measure12V,repairthe relatedwire.
9. Disconnect thejumperwire.
22.10 FUELSYSTEM
,,r
I FuelPumpAssembly
2 FuelPumpAssembly
l
ElectricalConneclor
HoldPressure
Do this inspectionif the pumpoperationinspectionis 6. Turn the ignitionswitchon for 10 secondslo runthe
notas soecified. luel pump.
1. Disconnectthe negativebatteryterminal. 7. Tum the ignitionswitcholf and removethejumper
wtre.
2. Releasefuel systempressure.Referto "Releasing
FuelSystemPressure"in this section. 8. Observethe fuelpressureafter5 minutes.
3. Connecta fuel pressuregaugeto the fuel filterand Fuel pressure:Morethan 50 psi (340kPa)
plugthe outletof the gaugeas shown.(lnstall 9. lf not as noted,replacethe fuel pump.
clampsas shown.)
Fuel PumpMaximumPressure
1. Disconneclthe negativebatteryterminal.
2. Releasefuel systempressure.Referto "Releasing
Fuel SystemPressure"in this section.
3. Connecta fuel pressuregaugeto the fuelfilterand
plug the oulletof the gaugeas shown.(lnstall
clampsas shown.)
4. Connectthe negativebatteryterminal.
5. Connectthe datalink connectorterminalsFUEL
PUMPand B+ witha jumperwire.
6. Tum the ignilionswitchon io run thetuelpump.
7. Measurethe fuel pumpmaximumpressure.
Fuel pump maximumpressure:above50 psi
(340 kPa)
8. Turn the ignitionswitchoff and removetheiumper
wtre.
9. lf this pressureis not measured.reDlace
thefuel
pump.
4. Connectthe negativebatery lerminal.
A WARNING
THEFUELSYSTEMREMA]NSUNDER FUELPUMPRELAYINSPECTION
PRESSURE WHENTHEENGINEIS NOT
RUNNING. RELEASEFUELSYSTEMPRESSURE CheckOperation
BEFOREDISCONNECTING ANY FUELLINETO A wlRtttttC
REDUCETHECHANCEOF PERSONAL INJURY THE FUELSYSTEMREMAINSUNDER
OR FIREDAMAGETO VEHICLECOMPONENTS. PRESSURE WHENTHEENGINEIS NOT
Connectthe datalinkconnectorterminalsFUEL BUNNING. RELEASE
FUELSYSTEMPRESSURE
PUMPand B+ witha jumper
wire. EEFORE DISCONNECTING
ANY FUELLINETO
REDUCETHECHANCEOF PERSONAL INJURY
OR FIREDAMAGETO VEHICLECOMPONENTS.
FUEL SYSTEM 22-11
KArSllt{r€
Connectthe datalinkconnectorterminalsFUEL
PRESSURE REGULATOR PUMPand B+ witha jumperwire.
INSPECTION Tumthe ignitionswitchon tor 10 seconds to run
thefuelpump.
FuelLine Pressure 7. Tumthe ignitionswitchoff and removethe jumper
1. Disconnectthe negativebatteryterminal. wire.
2. Releasefuelsystempressure.Referto "Releasing Pinchthe fuel returnhoseat the regulatorwith
FuelSystemPressure"in thissection. pliers.
3. Connecta luel pressuregaugeto the pressureport Observethe fuel oressurefor 5 minutes.
locatedon the frontof the fuel rail.
Fuel pressure:Morethan 21 psi (147kPa)
4. Connectthe negativebatteryterminal.
10. lf not as noted,replacethe pressureregulator.
5. Startthe engineand run it at idle. Referto the pressureregulatorreplacement sleps
6. Inspectthe fuel line pressuremeasurement. locatedin this manual.
Fuel line prcssure: 34 psi (235kPa)
7. Disconnectthe vacuumhoselromthe Dressure
regulatorand measurethe fuellinepressure.
Fuel line pressure:42 psi (292.5kPa)
Hold Pressure
Do this inspectionif the fuel line pressureinspectionis
not as noted.
1. Disconnect the negativebatteryterminal.
xtar6g-22{+s
22-12 FUELSYSTEM
FUELINJECTORINSPECTION
CheckOperation
1. Warmup the engineandlet it idle.
2. Listenfor the soundof eachiniectorrunningby
usinga soundscopeor a screwdriver.
A mnHrnc
FUELIS EXPLOSIVE.
WHENWORKINGON
FUELSYSTEMPARTS,MAKESURETO SUPPLY
ADEOUATEVENTILATION
TO THEWORK
AREA.DO NOTSMOKE.ANDKEEPSPARKS
AND OPENFLAMESAWAY.
KAtS$22-tqs
,
Connectthe datalinkconnectorterminalsFUEL
PUMPand B+ witha jumperwire.
4. Tum the ignition switchon.
5 . l'ilt the injectorsabout60 degreesandverifythat
no fuel leakstromthe iniectornozzles.
o . lf fuel leaks,replacethe leakinginjector.
Referto
"On-Vehicle Service"in this section.
7. Turnthe ignitionswitch"OFF and removethe
jumperwrre.
xtat 63-224\5
't
Caution
Make surc the fuel injectorc are firmly seated on
the tuel rail to prevent movementancl possible
damage,
3. lf no soundis heard,measureinjectorresisiance.
4. lf the iniecloris OK, checkwiringto the inieciorand
the voltagesof the ECMterminals16, 17, 34 and {tai 6i}22.tx\s
35.
5. lf removalof the iniectorsystemis needed,referto
"On-Vehicle Service"in this sectionfor the sieos.
FuelLeakageTest VolumeTest
'I. Takeout the iniectorstogether
withthe fuel rail. 1. Takeout the injectorstogetherwiththe fuelrail.
2. Securethe iniectorsto the tuel railwithwire. 2. Securethe injectorslo the distributorpipewith
wrre.
3. Connectan injectortesterto the batteryandthe
iniector.
4. Inspectthe injectorvolumewith a graduated
container.
Iniectorvolume:130cm' (130cc, 7.95)/min
FUELSYSTEM22.13
5. lf not as noted,replacethe injectors.Referlo 'On-
VehicleService'in this section. ON-VEHICLE
SERVICE
* Notice FUELTANK
. Always use new injectorO-ringswhen replacing Removal
injectors.
. Apply a small amountof cleanengine oil to each
A unnrrue
FUELIS EXPLOSIVE. AN EMPTYFUELTANK
of the O+ings beforeinstalling. CAN STILLCONTAINEXPLOSIVE GASES.
SUPPLYADEQUATEVENTILATION TO THE
WORKABEA.DO NOTSMOKEANDKEEP
SPARKSANDOPENFLAMESAWAY.PURGE
FUMESFROMTHETANKAS SOONAS
POSSIBLE.
1. Disconnectthe negativeterminalfromthebaftery.
2. Ooenthe rearaccessdoor of the vehicle.
3. Releasethe catchfor the rearseatandtilt it out of
lhe way.
4. Pull backthe souareof carDetin the areabehind
the tiltedseatwhichcoversthe fuelpumpassembly
accesspanelon the vehicletloor.
5. Disconnectthe two halvesof the fueloumo
assemblvelectricalconnector.
|(|Ar6+A-rl.s
,,r//
InjectorResistance
1. Disconnectthe iniectorharness.
2. Measureresistanceof the injector.
Resistance:12 -16f) @ 68'F (20'C)
3. lf not noted,replacethe injector.Referto "on-
VehicleService"in this seclionfor steos.
1 FuelPumpAssembly
2 FuelPumpAssembly
EleclricalConnector
xtal63,z-.t3€
6. Removethescrewholdingthe groundwirelugto
grouno.
7. Removethe four screwsattachingthe accesscover
and removethe accesscover,movingit out of the
way.
8. Removetwo fuel hoseclampsfromthe two fuel
hoseassemblies connectedto the fuelpump
assembly.
9. Disconnectthe twoluel hoseassemblies tromthe
fuelpumpassembly.
10. Disconnectfueltankpressuresensorelectrical
Ktar 6922-t2€ conneclor.
11. Workingthroughthe accessport,removethe three
fuel hoseclampsfromwherethethree{uel hoses
are connectedto the fuel iank.
22-14 FUELSYSTEM
Installation
A wlnNrlc
FUEL15 EXPLOSIVE. AN EMPTYFUELTANK
CAN STILLCONTAINEXPLOSIVEGASES.
SUPPLYADEQUATEVENTILATION TO THE
WORKAREA.OO NOTSMOKEAND KEEP
SPARKSAND OPENFLAMESAWAY.PURGE
FUMESFROMTHETANKAS SOONAS
POSSIBLE.
t . Raisethe vehicleon a hydrauliclift to the normal
undercarriage servicinglevel.
2. Attachthe shieldto the iuel tank usinotwo
attachingbolts.
Ensureany protectivecapsare removedfromthe
fuel tank oorts.
4. Placethe fueltank on a liftingdeviceeodcarefully
xtat 61t-22.ta-s
raisethe fueltank assemblyunderthe raised
12. Disconnectthe threefuel hosesfromthe nozzles vehicleuntilthe assemblyis positionedat the point
on the fueltank. ot installation.
13. Loosenthe inlethoseassembly jointclamp. Installtive l5 mm boltsto fastenthe fuel
14. Raisethe vehicleon a hydrauliclift to the normal tanldshieldassemblyinto placeon the vehicle
undercarriage chassis.
servicinglevel.
15. Usinga liftingdevice,raisethe liftingdeviceto the
bottomof the fueltank in the vehicle.Centerthe
liftingdeviceon the fueltanldshieldassembly.
16. Removelive 15 mm boltsfrom the fueltanldshield
assembly.
17. Carefullypullthe fueltanldshieldassemblvawav
fromthe chassisof the vehicleand allowihe
assemblyto reston the liftingdevice.
18. Lowerthe liftingdeviceand placethe fueltanU
shieldassemblyon a work bencharea.
't
Caution
Cover the open ports on the fuel tenk with
plastic caps or otlEr aveilable covers to avoid
luel vapor contaminating the work area.
19. Separatethe fueltankfromthe shieldby removing 1 FuelTank
two attachingbolts.Liftthe luel tank awayfromthe 2 Shield
shieldand storetheshield.
1 FuelPumpAssembly
FuelPumpAssembly
ElectricalConnector
xar ql-zt. r0€
* Notice
Do not use any excessiveforce on the fuel pump
assembly.Thepafts are delicate, suchas the fuel (:
screen which might be damagedby incorrect
rcmoval from the fuel tank.
9. Disconnectthe two fuel hosesfromthe fueloumo
assembly.
10. Bemoveeightretainingscrewsaroundthe top
surfaceof the fuel pumpassembly.
11. Whiletwistingverycarefully andtiltingthefuel
pumpassembly, pullgradually
untilit comesoutof
the top of the tueltank assembly.
'12.Whenthe fuelpump
assemblyis completelytaken
out of the accessarea,wrapit in a shoptowel
carefullyuntil it reachesthe maintenance area.
13. Sealofi the oDenJueltank Dortwitha coveror Kta163-22-22€
plug.
Holdingthefuelpumpassembly, guideit intothe
accessporton the top o{ the iuel tankas far as it
will go at that point.
Whiletwistingverycarefully,and tiltingthe luel
pumpassembly, pushgraduallyuntiltheassembly
seatsin the fueltankcorrectly.
Installeightretainingscrewsaroundthe top of the
installedfuel pumpassembly.
BNr422003
lnstallation
A unrurnc
FUELIS EXPLOSIVE. WHENWORKING ON K4163-22-?!15
FUELSYSTEMPARTS,MAKE SURETO
SUPPLYADEOUATEVENTILATION TO THE Connectthe two fuel hosesto the fueloumo
WORKAFEA,DO NOTSMOKEANDKEEP assembly.
SPARKSAND OPENFLAMESAWAY. 6 . Installthe two fuel hoseclampsto the twotuel
* Notice assembliesconnectedto the fuel pumpassembly.
Do not force fuel/ pump assemblyparts. The fuel/ 7. Inserithegroundwirein the fuelpumpassembly
screen is delicateand can be damagedby connectorassemblythroughthe accessholein the
improperinstallationto the fuel tank accesscover.
1. Removeany cap or protectivecoverirom the port 8. lnstallthe tour retainingscrewsattachingthe
on the loo of the fuel tank. accesscoverto the flooringof the vehicle.
9 . Attachthe groundwire lug to the flooringof the
vehiclewiththe atlachingscrew.
1 0 .Connectthe hvohalvesof the fuel pumpassembly
electricalconnector.
FUELSYSTEM22-17
1 FuelPumpAssembly
2 FuelPumpAssembly
Eleclrical
Conneclor x|Are22-rls
KtAl6+22-t+S
11. Placethe adhesivetape overthe loosewiringand Removethe two fuel hoseclampsfromthe twotuel
putthe squareof carpetingbackoverthe areaof hoseassembliesconnectedto the tuelpump
the accessdoorbehindthe rearseat. assembly.
12. Releasethe catchlor the rearseatand tilt it back Notice
intothe normalposition. Do not force fuel pump assemblypafts. The fuel
screenis delicateand can be damagedby
13. Closethe rearaccessdoorof the vehicle. improperremoval from the fuel tank.
14. Connectthe negativeterminalto the battery. a Disconnect the two fuel hosesfromthe fuel oumo
assembly.
1 0 .Disconnect fuel tank pressuresensorelectrical
connector.
FUELPUMPASSEMBLY
FILTEB 1.1. Removeeightretainingscrewsaroundthe top
surfaceot the fuel pumpassembly.
Removal 12. Whiletwistingvery carefullyand tiltingthe tuel
A wlnNrt'to pumpassembly,pullgraduallyon the assembly
FUELIS EXPLOSIVE. WHENWORKING ON untilit comesout of the too of the fueltank.
FUELSYSTEMPARTS,MAKESURETO
SUPPLYADEOUATEVENTILATION TO THE
WORKAREA.DO NOTSMOKEANDKEEP
SPARKSAND OPENFLAMESAWAY.
1. Disconnect the negativeterminaltromthe battery.
2. Openthe rearaccessdoorof the vehicle.
3. Releasethe catchfor the backseatand tilt it out of
the way.
4. Pullbackthe squareol carpetin the areabehind
the tiltedseatwhichcoversthe fuel pumpassembly
accessoanelon the vehiclefloor.
5. Disconnect the two halvesof the fuelpump
assemblyelectricalconnector.
6. Removethe screwholdingthe groundwire lug to
ground.
\
7. Removethe four screwsattachingthe accesscover
aNra220qt
and removethe accesscover,movingit out ol the
wav.
xtarc+22.a2s
\S-.....-o
I Fuel pump
2 Clip \
3 Screen
4 Pressure sensor for
leakage check of <) ..- 2 xat6+zt-r+s
vapor Ine
5 Nut * Notice
6 Dust Protection
tube lor sensor Do not force fuelpump assembly parts.Thefuel
aN7A22m5
screen is delicateand can be damagedby
improper rcmovaltrom the tank.
Whiletwistingverycarefully,and tiltingthefuel
pump assembly, pushgraduallyuntilthe assembly
lnstallation seats in the fueltankcorrectly.
A wlRntttc
FUELIS EXPLOSIVE. WHENWORKINGON
FUELSYSTEMPARTS,MAKESURETO
SUPPLYADEOUATEVENTILATION TO THE
WORKAREA.DO NOTSMOKEANDKEEP
SPARKSAND OPENFLAMESAWAY.
1. Removeany cap or protectivecoverfromthe port
on the too of the fuel tank.
x|Atdlzt-2ars
FUELSYSTEM 22.19
FUELPUMP
Removal
A unHrHc
FUELIS EXPLOSIVE. WHENWORKING ON
FUELSYSTEMPARTS.MAKESURETO
SUPPLYADEQUATEVENTILATION TO THE
WORKAREA.DO NOTSMOKEANDKEEP
SPARKSAND OPENFLAMESAWAY.
1. Disconnectthe negativeterminaltromthe battery.
2. Openthe rearaccessdoorof the vehicle.
3. Releasethe catchfor the backseatand tilt it out of \
the way.
BN7A22i 03
22-20 FUELSYSTEM
BN7A22(p3
I
Holdingthe fuelpumpassembty,guideit intothe
accessport on the top of the fuel tank as far as it
will go at that point.
1
2
ama2zr06
Installation
\
A wanHrl'tc BN7A2200g
KAi 6322-2aS
FUELSYSTEM 22-21
6. Installeightscrewsaroundthe top surfaceof the 1. Disconnect the negativeterminalfromthe battery.
fuel pumpassembly.
2. Openthe rearaccessdoorof the vehicle.
7. Connectthe two fuel hosesto the luel pump
assembly. 3. Releasethe catchtor the backseatandtilt it out of
the way.
8. Installthe two fuel hoseclampsto the two fuel
hosesconnectedto the fuel pumpassembly. 4. Pull backthe squareof carpeiin theareabehind
the tiltedseatwhichcoversthe fuelpumpassembly
9. Installfueltank oressuresensor. accessoanelon the vehiclefloor.
10. Connectfueltank pressuresensorelectrical 5. Disconnect the two halvesof the fuelpump
connector. assemblyelectricalconnector.
1l. Insertthe groundwireandthefuelpumpelectrical 6. Removethe screwholdingthe groundwire lug to
connectorwiresthroughthe accessholein the ground.
accessdoorand mountit overthe accesshole.
7. Removethe four screwsattachingtheaccesscover
12. Installfourscrewsto securethe accessdoorto the and removethe accesscover,movingit out of the
vehicleflooring. way.
13. Installthegroundwirelugto thefloorwiththe
attachingscrew.
'14.Connectthe two
halvesof the fuel pumpassembly
electricalconnector.
15. Attachadhesivetapeto any loosewiringand cover
the areaof the installedaccessdoorwiththe
squareof carpeting.
'16.Release
the catchfor the rearseatand out it to the
normaloosition.
'17.Closethe rear
accessdoorof lhe vehicle.
18. Connectthe negativeterminalto the battery
KAr e&22-lihs
A wlnHrHc
FUELIS EXPLOSIVE.
WHENWORKING ON
FUELSYSTEMPARTS,MAKESURETO
SUPPLYADEOUATEVENTILATION
TO THE
WORKAREA.DO NOTSMOKE.AND KEEP
SPARKSAND OPENFLAMESAWAY.
22-22 FUELSYSTEM
\
aN7A2i!@
s--=l
sfu'-s
V'
1 FuelPumpAssembly
FuelTank \
SenderAssembly
3 FuelTankPressure
Sensor aNra22003
4N7A22007
* Notice
Do not force fuel pump assemblyparts. The fuel
Installation screenis delicate,and can be damagedby
A mRHlHc improperinstallationto the fuel tanK.
FUELIS EXPLOSIVE. WHENWOFKINGON Whiletwistingverycarefullyand tiltingthe fuel
FUELSYSTEMPARTS,MAKE SURETO pumpassembly, pushgradually on the assembly
SUPPLYADEOUATEVENTILATION TO THE untilit goes in positionin the fuel tank assembly.
WORKAREA.DO NOT SMOKEAND KEEP Installeightscrewsaroundthe top surfaceof the
SPARKSAND OPENFLAMESAWAY, fuel pumpassembly.
1. Installthe retaininghardwarethat holdsihe fuel Connectthe two fuel hosesassembliesto the fuel
senderassemblyto the fuel pumpassembly. pumpassembly.
2. Removeany capor protectivecoverfromthe port 7 . Installthe two tuel hoseclampsto the two fuel
on the toDol the fuel tank. hosesconnectedto the fuel pumpassembly.
Connectfuel tank pressuresensorelectrical
connector.